pcm 24 manual

PCM-24 Press FeedController

Information furnished by EMERSON EMC is believed to be accurate andreliable. However, no responsibility is assumed by EMERSON EMC forits use. EMERSON EMC reserves the right to change the design oroperation of the equipment described herein and any associated motionproducts without notice. EMERSON EMC also assumes no responsibilityfor any errors that may appear in this document. Information indocument is subject to change without notice.

P/N 400292-00 Rev: A2

Date: Feb. 28, 1996

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Customer Services:EMERSON EMC offers a wide range of services to support our customersneeds. Listed below are some examples of these services.

Service Support (612)-474-8833Emerson Electronic Motion Controls products are backed by a team ofprofessionals who will service your installation wherever it may be. Ourcustomer service center in Minneapolis Minnesota, is ready to help yousolve those occasional problems over the telephone.

Our customer service center is available 24 hours a day for emergencyservice to help speed any problem solving. Also, all hardware replacementparts, should they ever be needed, are available through our customerservice organization.

Need on-site help? Emerson EMC provides on-site service, in most cases,the next day. Just call Emerson EMCs customer service center when on-site service or maintenance is required.

Training Services (612)-474-1116Emerson EMC maintains a highly trained staff of instructors tofamiliarize customers with Emerson EMC products and theirapplications. A number of courses are offered, many of which can betaught in your plant upon request.

Application EngineeringAn experienced staff of factory application engineers provide completecustomer support for tough or complex applications. Our engineers offeryou a broad base of experience and knowledge of electronic motion controlapplications.

EMERSON BBS (612) 474-8835.PCX Software updates can be obtained from the Emerson BBS. 300 - 9600Baud, N, 8, 1.

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Table Of ContentsCUSTOMER SERVICES:.........................................................................................II

SERVICE SUPPORT (612)-474-8833 .......................................................................IITRAINING SERVICES (612)-474-1116 ....................................................................IIAPPLICATION ENGINEERING..................................................................................IIEMERSON BBS (612) 474-8835.........................................................................IITABLE OF CONTENTS...........................................................................................III

PCM-24 OVERVIEW.................................................................................................1

NAVIGATING PCX SOFTWARE............................................................................3

INSTALLING YOUR PCM-24..................................................................................5

Inputs .....................................................................................................................................................................6Outputs...................................................................................................................................................................6

PRESS FEED THEORY OF OPERATION.............................................................7

PCM-24 TERM DEFINITIONS: ................................................................................8TYPES OF PRESS FEEDS .........................................................................................9PRESS FEED MODES OF OPERATION....................................................................10

Manual Mode.......................................................................................................................................................10Setup Mode..........................................................................................................................................................10Automatic Mode..................................................................................................................................................12Roll Control.........................................................................................................................................................12

JOG FUNCTIONS...................................................................................................15

PCM-24 SETUP ........................................................................................................16

PRESS FEED SCREEN ...........................................................................................18Feed Cycle Type..................................................................................................................................................18Feed Cycle Start-up Configuration......................................................................................................................18Feed Angle Orientation........................................................................................................................................19Complete Outputs................................................................................................................................................19Select Serial Default Program By:.......................................................................................................................20Early Warning Part Count....................................................................................................................................20Feed Cycle Timeout.............................................................................................................................................20Manual Setup Mode Delays.................................................................................................................................20

LOOP CONTROL SCREEN......................................................................................22Maximum Loop Speed.........................................................................................................................................22Max Loop Speed Reference (Max Voltage)........................................................................................................22Voltage Change Rate Limit..................................................................................................................................23Loop Speed Increase/Decrease Increment...........................................................................................................23Cycle Start Strokes Rate......................................................................................................................................23Target Voltage Weighting Factor........................................................................................................................24Analog Jog Velocity............................................................................................................................................24

DRIVE PARAMETERS SCREEN..............................................................................25Axis ID Description.............................................................................................................................................25

MASTER AXIS SCREEN ........................................................................................26Master Axis Setup................................................................................................................................................26

PROGRAMMABLE LIMIT SWITCHES (PLS)............................................................31PLS Setup............................................................................................................................................................32

INTERNAL INPUT AND OUTPUT LINES..................................................................34PCM-24 INPUT/OUTPUT FUNCTIONS...................................................................38

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Input Functions....................................................................................................................................................38PCM-24 Output Functions...................................................................................................................................43

INDEXES USING A PCM-24.................................................................................47Continuous Compensation Mode.........................................................................................................................47Re-index Compensation Mode.............................................................................................................................48

RE-INDEX SCREEN ..............................................................................................49Re-index Functions Definitions...........................................................................................................................49

ADVANCED PROGRAMMING FEATURES...............................................................51Global External Input Time Limit........................................................................................................................51Synchronized Jog.................................................................................................................................................52User Registers......................................................................................................................................................53Equations .............................................................................................................................................................54User Messages.....................................................................................................................................................57

PCM-24 PROGRAMS..............................................................................................58

Job Type Programs..............................................................................................................................................58Job Queue Programs............................................................................................................................................58PCM-24 Programming Example..........................................................................................................................59

BUILDING YOUR PROGRAM.................................................................................65Time Base (Indexes And Homes)........................................................................................................................89Programming Functions.......................................................................................................................................67

SUSPEND/RESUME FUNCTIONS............................................................................86MULTI AXIS SYNCHRONIZATION..........................................................................89ENCODER OPERATION.........................................................................................90

Single Encoder Operation....................................................................................................................................90

APPENDIX A - 12 BIT ANALOG OUTPUT.........................................................93

APPENDIX B - 12 BIT ANALOG INPUT..............................................................95

APPENDIX C - PCM-24 TIMING DIAGRAMS...................................................96

APPENDIX D - LIST OF FIGURES.....................................................................100

PCM-24 Operators Manual

1

PCM-24 OverviewThis manual provides setup and programming information for the PCM-24 Press Feed Controller using PCX software. The PCM-24 applicationmodule attaches to any EMERSON EMC FX Drive.

The PCM-24 controls your press feed application using two modes ofoperation: Manual and Automatic. These two press feed modes areselected with input functions (see inputs on page 38). The primaryfunction of the manual mode is to set up and test the press feed systemwhile the Automatic mode is primarily used for production runs.

The PCM-24 allows also an FX drive to compensate for product slippageso that consistent and precise product positioning can be maintained.Slippage may be caused by friction or mechanical deficiencies in a system.

To simplify and expand the flexibility of machines and processes, thePCM-24 can synchronize its motion to a master axis. Master axisreference signals can come from either an upstream FX drive or from asynchronization encoder.

Features provided by the PCM-24 Press Feed Controller include: Two modes of operation (Manual mode and Setup mode).

Slip Compensation which automatically compensates for product slip to maintain precise position.

250 indexes (as opposed to 32 indexes in the base FX drive)

99 programs and a maximum of 1,024 program steps

Flying Cutoff program for accurate length cuts for almost any process

Wait to continue function that halts program flow until selected internal and/or external input lines becomeactive

Jump function to other parts of the program depending on the condition of the selected internal and/or externalinput lines

Programmable internal and external output lines that become active depending on program instructions

Programmable Limit Switch option for programmable output lines

Suspend/Resume Program function that records existing program data at time of interruption and permitslater completion of the interrupted program

Compound Index function that changes motor velocity at completion of compounded index distance to velocity ofnext index without stopping

Logic, math, and branching functions that control program flow based on current conditions.


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The firmware revision on a PCM-24 module necessary for all of theprogramming features in this manual is A1 or higher. You can find therevision number of your module by looking at the serial number stickerlocated on the side of the module. The revision number is found in the"REV" field.

The PCX version that is shipped with this Application Module will workwith previous revisions of EMERSON EMC Application Modules and FXDrives. However, some of the features described in this manual will notbe available for use with earlier equipment and will not appear on screenwhen on-line with PCX6.05.

It is important that you become familiar with "PCX Software Setup andOperation" in the FX Drive Operator's Installation and ProgrammingManual (P/N 400282-00). It provides the basic information needed to setup and program the FX drive using PCX software (ver. 6.6 or above).

The FX Drive's firmware is disabled whenever an Application Modulesuch as the PCM-24 is attached. Therefore, the FX Drive's firmware canbe any version since the programming features reside in the ApplicationModule's non-volatile memory.

The PCM-24 stores FX Drive setup parameters within the PCM-24module. This allows you to transfer the PCM-24 to another FX Amplifierwithout losing setup parameters.


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Navigating PCX SoftwareAdding a PCM-24 Press Feed Controller to an FX Drive gives you severaladditional features in PCX. The hierarchy menu diagrams in Figures 1and 2 show the additional features in the darker shaded blocks.

Figure 1 Hierarchy Diagram #1


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Figure 2 Hierarchy Diagram #2


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Installing Your PCM-24The PCM-24 Press Feed Controller attaches to the front of any FXAmplifier with two locking arms. All electrical connections (except I/O)are made via the 48 pin connector.

The PCM-24 is equipped with 8 input lines and 4 output lines, doublingthe I/O capability of the standard FX drive. All inputs and outputs areoptically isolated for +10 to +30 VDC operation. Each input and outputline has 2 screw terminals associated with it to provide for either currentsinking or current sourcing operation.

18 to 24 gauge wire must be used for I/O wiring. The use of larger gaugewire will cause the I/O terminals to prematurely fatigue.

The first 8 pairs of terminals (numbered 13 - 20) are inputs and the last 4pairs of terminals (numbered 21 - 24) are outputs. The outputs arecapable of sinking or sourcing 200 mA. You must limit the output currentto less than or equal to 200 mA per line. See Figure 3 for I/O connectionexamples.

Figure 3 PCM-24 Installation And I/O Connections


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InputsInputs require an external voltage/current source for operation. Thisvoltage source must be in a range of 10.5 to 30 VDC. The (-) lead of theexternal power supply must be connected to enclosure or safety ground.

OutputsOutputs are similar to inputs in that they can be connected to eithersinking or sourcing type loads. Outputs require an external isolatedsupply voltage, usually the same supply as the inputs. Each output cansink or source 0.2 amps DC. The (-) lead of the external power supplymust be connected to enclosure or safety ground.

If inductive loads such as DC relay coils are connected to the outputs, asuppression diode must be installed in parallel with the load coil with thecathode towards the positive end of the external power.


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Press Feed Theory of OperationMany different configurations for press feed applications exist. Thismanual provides a basic understanding of some common press feedconfigurations and how the PCM-24 Press Feed Controller can be used tosolve these applications.

Any given system may have more or less components depending on thecomplexity of the application. The minimal system components requiredto employ a PCM-24 Press Feed Controller would be the press itself and aset of feed rolls to advance the product to be pressed. The components of atypical press feed system are depicted in the figure below.

High/LowLoop Limit

Feed Roll

PCM-24

FX Drive

T-60OperatorInterface

Analog Drive

Analog Motor

DX Motor

Sensors

Sync.Encoder

PCM-24B

Figure 4 PCM-24 Application


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PCM-24 Term Definitions:The following terms are used in this manual to describe various PCM-24functions.

Batch

A Batch is defined as the part count in the PCX job type program screen.The batch counting feature helps facilitate the breakdown of productsbeing counted. The number of batches in a job is entered as the batchcount in the PCX program screen.

Job

A Job is the total # of parts that are produced as a result of a singleprogram initiate input to the PCM-24. This number will be the product ofthe part count and the batch count.

Part

A Part is what is produced by the code within the body of a PCXprogram. The part is complete when the program complete output comeson. The number of parts in a batch is entered as the part count in thePCX program screen.

Press

Throughout this manual the term Press means your machineselectronics, sensors or signals as a result of motion of the press.

Feed Length

The Feed Length is the distance the product (or material being pressed)will advance through the press during the feed portion of the press feedcycle. The Feed length value is actually the Index Distance of the indexused in the PCX program.

Press Feed Angle

The Press Feed Angle is the portion of the press feed cycle defined astime during which the product must be advanced by the Feed Length (orIndex Distance) amount.

Servo Feed

The portion of the press that is responsible for feeding product accordingto a specific part length.


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Types of Press FeedsThe type of press feed is selectedwith the Feed Cycle Typeparameter in the Press Feedsetup screen.

Understanding the operation of the PCM-24 in a press feed applicationbegins with a definition of the types of press feed systems. Most pressfeeds can be classified into one of two types based on the nature ofpress/feed interaction. These types are Continuous press feeds andIntermittent press feeds.

Both types of feeds require intermittent start and stop motion commandsfrom the PCM-24, however, the interaction and coordination between thepress and the PCM-24 occurs differently.

Continuous Press Feeds

In a continuous press feed application the 360 degree press feed cycle isdivided into a Press Portion and a Feed Portion . The product must bestationary during the press portion of the press feed cycle. The timerequired for the press portion begins just before the press is in contactwith the material and ends when the press is no longer in contact withthe material.

The remaining time of the press feed cycle is defined as the Press FeedAngle during which the product must be advanced by the defined FeedLength amount.

While in the continuous mode of operation, the press gives the PCM-24feed initiate signals at the defined cycle rate to trigger motion. The pressassumes it is safe to press again and does not receive any kind of "feedcomplete" signal from the PCM-24 before it begins the next press feedcycle.

Due to the autonomous nature of the continuous press feed system, thethroughput rate is determined by the cycling rate of the press based onthe assumption that the FX Drive is sized appropriately to keep up.

If the press goes faster, the servo feed must go faster to keep up in aproportional fashion. If the servo feed is not capable of completing itsmotion during the feed portion of the press cycle, a feed fault will occur.

Intermittent Press Feed

In an intermittent press feed application, the 360 degree press feed cycleinvolves bi-directional signal handshaking to initiate motion of eithersystem. Motion of the servo feed is initiated by the press when the pressportion of the press feed cycle is complete.

When the servo feed has completed the feed portion of the press feedcycle, the PCM-24 must signal the press controller that the feed motionhas been completed so that the press can cycle again.

Due to the handshaking nature of intermittent press feed applications,the overall throughput of the press feed system is determined bywhichever mechanism cycles the slowest, the press itself or the servofeed. In this type of press feed system, the entire system is limited by theslowest (weakest) link.


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Press Feed Modes of OperationThe PCM-24 has two primary modes of operation and one secondarymode of operation. The two primary modes of operation are manual modeand automatic mode. The secondary mode of operation is a sub-mode ofthe manual mode called setup mode. These three different press feedmodes are selected with input functions (see inputs on page 38).

Feed moves made in manual mode are generally thought of as motioninitiated by the operator, while feed moves made in the automatic modeare generally initiated by the press controller. The primary function ofthe manual mode is to set up and test the press feed system while theAutomatic mode is primarily used for production runs.

If motion is in progress and a mode transition occurs, motion willbe stopped before the new mode is entered. If the PCM-24 is inAutomatic mode when a mode change input is received, thecurrent feed length will be completed before motion will isstopped

Manual ModeThe purpose of the manual mode is to check the mechanics of the systemwhich includes feed capability and roll opening/closing. This allows you totest the configuration of the press feed in a single step fashion.

Entering Manual Mode

The PCM-24 is in manual mode if the Automatic Mode/Manual Modeinput (Input Function #81) is cleared .

While in the manual mode the manual mode output (output function#49), if assigned, will be on, anti-backup as well as feed rolls can beopened or closed, and the drive can be jogged.

Some manual mode features require that the PCM-24 also be in setupmode, a sub-mode of manual mode. This is especially true for Anti-Backup and Feed Roll open/close control and jog control. The parametersin the Press Feed screen (see Press Feed screen on page 18) are used tosetup the PCM-24 features specific to the manual mode.

Setup ModeThe purpose of the setup mode is to allow you to test the configuration ofthe press feed in a single step fashion using jog functions and the FeedNext Part and Feed Previous Part inputs (input functions #84 & 85respectively, see page 40 for descriptions of these inputs).


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Entering Setup Mode

To enter setup mode, set input function #82 (Setup Mode) and clear inputfunction #81 (Automatic Mode). Upon entering the setup mode, the setupmode output is set (output function #50) and the drive position is reset tozero. The PCM-24 position is always reset to zero upon entering Setupmode.

Using Jog In Setup Mode

The Jog + (input function #5) and Jog - (input function #6) functions inthe setup mode will allow the FX Drive motor to move within a singlefeed length in the positive or negative directions respectively.

If a jog + is the first jog function initiated after entering setup mode, thePCM-24 will restrict motion between the zero position and plus one feedlength in the positive direction. If a jog - is the first jog function afterentering the setup mode, the PCM-24 will restrict motion between thezero position and minus one feed length.

The PCM-24 will only allow movement beyond a single feed length if arising edge feed initiate (input function #83) occurs when the drive is atthe jog starting position +/- one feed length. After a feed initiate, the FXDrive position will be reset to zero and the PCM-24 will again allowmovement of up to +/- one more feed length.

Using Next Part/Previous Part Inputs In Setup Mode

Pulsing the Next Part input (input function #84) will cause the FX Drivemotor to move forward at the jog velocity until it reaches the end of thecurrent range (either positive or negative).

Pulsing the Previous Part input (input function #85) will cause the FXDrive motor to move in the reverse direction at the jog velocity until itreaches the beginning of the current range (either positive or negative).

Exiting then re-enteringSetup mode will set a newzero position.

Figure 5 Press Feed Range

A Feed Initiate command (input function #83) while in Setup mode hasan effect only when you are at the end of the range (either positive ornegative).


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Automatic ModeThe main purpose of the automatic mode is to make production runs.

Entering Automatic Mode

The PCM-24 is in automatic mode when the Automatic Mode/ManualMode input (input function #81) is on. When the automatic mode isentered the manual and/or setup mode output(s) are cleared, theAutomatic Mode output (output function #48) is on and the Feed Faultoutput (output function #56) is cleared.

Exiting Automatic Mode

When exiting the Automatic Mode the FX Drive is commanded to stop,the Feed In Motion and Automatic outputs are cleared and the manualOutput is set.


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Roll ControlThe feed and anti-backup rolls can be controlled through the PCM-24with the Open/Close Feed Rolls and Open/Close Anti-Backup Rolls inputfunctions (input functions 95, 96 , 97 and 98 respectively). The nature ofroll control can be Edge or Level Sensitive depending on whether theClose Feed Roll input function is assigned.

There are also two output functions (output functions 51 and 52)available which indicate the condition of the feed and anti-backup rollsrespectively.

The PCM-24 can be programmed to open the feed rolls and close the anti-backup rolls upon power up or when the FX Drive is inhibited.

Manual Mode Roll ControlWhile in manual and/or setup mode, input functions 95, 96, 97 and 98 canbe used in setup, maintenance and troubleshooting procedures. If theClose Feed Rolls input is assigned, the Open Feed Rolls input is edgesensitive and works in conjunction with the Close Feed Rolls input.

Feed Roll Control

If you are operating in manual mode with the Close Feed Rolls inputclear, a rising edge on the Open Feed Rolls input will:

open the feed rolls

clear the Feed Rolls Closed output.

If in manual mode with the Open Rolls input clear, a rising edge on theClose Feed Rolls input signal will:

close the feed rolls.

set the Feed Rolls Closed output.

If the Close Feed Rolls input is not assigned, the Open Feed Rolls inputwill be level sensitive. That is, when the Open Feed Rolls input is on thefeed rolls will be open and when the Open Feed Rolls input is off the feedrolls will be closed. In either case, the Feed Rolls Open delay (see FeedRolls Open Delay on page 21) will still apply.

Anti-Backup Roll Control

If in manual mode with the close anti-backup rolls input clear, a risingedge on the Open Anti-Backup Rolls input signal will:

open the anti-backup rolls.

set the anti-backup rolls opened output.

If in manual mode with the Open Anti-Backup Rolls and Jog Reverseinputs clear, a rising edge on the Close Anti-Backup Rolls input signalwill:

close the anti-backup rolls.

clear the anti-backup rolls opened output.


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If the Close Anti-Backup Rolls input is not assigned, the Open Anti-Backup Rolls input will be level sensitive. Which means, when theinput is on, the anti-backup rolls will be open and closed when the inputis off.

If the anti-backup rolls are closed and the PCM-24 receives a jog -, theanti-backup rolls will be opened and after the Reverse Jog Delay time hasexpired motion will begin. The Reverse Jog Delay has no affect if the anti-backup rolls are already opened. If the anti-backup roll are open as aresult of a jog reverse, the anti-backup rolls will be closed when the PCM-24 receives a jog forward input signal.

Automatic Mode Roll ControlRolls should be placed in the desired operating position before going intoAutomatic mode. Theoretically, no changes should be made to rollposition while the press is running in Automatic mode.


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Jog FunctionsThis section describes how the Jog functions work in a PCM-24 PressFeed application. You can use either the Jog Fast Velocity or the Jog SlowVelocity. The default Jog Velocity is Jog Fast. To use the Jog SlowVelocity, assign the Jog Slow input (input function #8).

The Jog screen is found by selecting Drive Setup, Define Motion then Jog(see Jog in the PCX section of the FX Drives manual P/N 400282-00).

Jog Forward

The drive will move forward at a rate defined by the jog velocityparameter in the PCX Jog setup screen when:

the Manual/Automatic Mode Input is clear.

the Setup Mode Input is clear.

the Jog Reverse (Jog -) Input is clear.

the Jog Forward (Jog +) Input is set.

Jog Reverse

The drive will move in reverse at a rate defined by the jog velocityparameter in the PCX Jog setup screen when:

the Automatic Mode Input is clear.

the Setup Mode Input is clear.

the Jog Forward (Jog +) Input is clear.

the Jog Reverse (Jog -) Input is set.

Jog Feed Forward (In Setup Mode)

The drive will move forward at jog velocity when: The Automatic Mode input is clear.

The Setup input is set.

The Jog Forward (Jog +) input is set.

The Jog Reverse (Jog -) input is clear.

Motion will proceed until The Jog Forward input is cleared or until thedrive reaches a position of plus one feed length Jog Feed Reverse (InSetup Mode).

Jog Feed Reverse (In Setup Mode)

The drive will move in reverse at Jog Velocity when: The Automatic mode input is clear the Setup input is set.

The Jog Forward (Jog +) input is clear.

The Jog Reverse (Jog - ) input is set.

The reverse jog delay has elapsed in the anti-backup rolls were closed.

Motion will proceed until the Jog Reverse input is cleared or until thedrive reaches a position equal to minus one feed length


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PCM-24 SetupIt is important that you become familiar with PCX software basic setupand operation in the FX Drives Operators manual (P/N 400282-00).

The PCX features necessary to run a Press Feed are listed below in theorder in which they should be addressed. Each feature listed must be setup before you can use them in a Press Feed application. Individual setupinformation for each feature is covered on the following pages.

1. Press Feed Screen: The first step is to setup the parameters in thePress Feed screen as they apply to your press. The Press Feed setupscreen is accessed by selecting Drive Setup, Drive Configuration thenPress Feed (see page 18).

2. Loop Control Screen: The next step is to setup the parameters in theLoop Control screen which apply to the 12 bit analog output. To setupthe analog loop parameters, choose the Loop Control option under theDrive Configuration menu in PCX (see Loop Control screen on page22. Also see 12 Bit Analog Output in Appendix A).

3. Drive Parameters: The next step is to define the parameters in theDrive Parameters screen. This screen is accessed by selecting DriveSetup, Drive Configuration then Drive Parameters. A description ofthe parameters in this screen (except for the Axis ID Description) canbe found in the PCX section of the FX Drives manual (P/N 400282-00). The Axis ID Description is an optional feature available onlywhen a PCM module is added to an FX drive and is described on page25 of this manual.

4. Master Axis (Signal Source): The next step is to setup theparameters in this screen which allow you to identify the SignalSource of the master axis. This step is only necessary if your systemwill be used to run synchronized indexes and/or slip compensationindexes. If your system is not running in sync mode or slipcompensation mode, you can skip this step. The Master Axis screen isfound by selecting Drive Setup, Drive Configuration then Master Axis(see page 26).

5. Programmable limit switches: The next step is to setup any followerPLSs your system may require. These are outputs that turn on or offat specified motor positions while feeding the press. The PLS screen isfound by selecting Drive Setup, Drive Configuration then PLS (seePLSs on page 31).

6. Assigning Input and Output Functions: There are 66 input and 38output functions available with a PCM-24 module. These I/Ofunctions can be assigned to any of the 16 external input (eight on thePCM-24 and eight on the FX drive) and 8 external output (four on thePCM-24 and four on the FX Drive).


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In addition to the external I/O lines, there are 16 internal input and16 internal output lines, giving you access to a total of 32 input(sixteen external and sixteen internal) and 24 output (eight externaland sixteen internal) lines per FX Drive With a PCM-24. Inputfunctions #81 through 101 and output functions #48 through 60 arespecific to Press Feed applications. The Input and Output screens arefound by selecting Drive Setup, Drive Configuration then eitherInputs or Outputs (see Assigning Input and Output Functions onpage ).

7. Press Feed Indexes: The PCM-24 is designed to accommodate up to 250 feeds (or indexes). A part will be definedas a single feed (index) or if desired a sequence of feeds (indexes). A job will be defined as a program that containsthe total number of parts. A description of the different Index types can be found in the PCX section of the FXDrives manual (P/N 400282-00). The Indexes screen is found by selecting Drive Setup, Define Motion then Indexes.

8. Advanced Programming Features: There are several advanced programming features such as Equations , UserRegisters , User Messages and Suspend/Resume functions that you can take advantage of. All of thesefeatures are explained in this manual starting on page 51.

9. Programs: The last step is to create a PCX program that executes one or more of the press feed Indexes as well asother programming functions your application may need (see programs on page 58). The Program screen is foundby selecting Drive Setup, Define Motion then Programs.

10. Analog Input: The PCM-24 can take a -10.0 VDC to +10.5 VDC signal from the 12 bit analog input which can beused for feedback from auxiliary analog references. A few examples are: Ultrasonic roll diameter sensor, dancerarm etc.. The input signal range is nominally -10.0 VDC to +10.5 VDC which corresponds to a data range of 0-4095decimal or 0-FFFh. (see page 93 for more information on the 12 bit analog input).


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Press Feed ScreenThe parameters in this screen allow you to configure the PCM-24 to yourmachine. The Press Feed setup screen is accessed by selecting DriveSetup, Drive Configuration then Press Feed.

Figure 6 Press Feed Screen

Feed Cycle TypeThis parameter allows you to choose the Type of feed cycle your presswill use, either Continuous or Intermittent (see Types Of Press Feeds onpage 8).

Note: In this release of the PCM-24, the following two press feed configurationsare not currently supported:

Intermittent Mode, Press Before Feed, Begin Feed Angle

Intermittent Mode, Feed Before Press, Begin Feed Angle

Feed Cycle Start-up ConfigurationThis parameter determines whether your press cycle begins with a PressStroke or a Product Feed. A Press Cycle is a motion sequence consistingof two functions, a Press Stroke and a Product Feed. One piece of productis completed at the end of each Press Cycle.

If the Press Before Feed option is selected, one piece is consideredcomplete after the Product Feed portion of the press cycle.

If the Feed Before Press option is selected, one piece is consideredcomplete after each Press Stroke portion of the press cycle.


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Feed Angle OrientationThis parameter is related to the duration of the Feed Initiate input (inputfunction #83) coming from the PCM-24. If the Full Feed Angle option isselected, the feed initiate signal is required to stay set for the entirePress Feed Angle (the Press Feed Angle is the portion of the PressCycle during which the press is not in contact with the material beingpressed).

If the initiate signal does not remain high for the entire feed angle, theFeed Fault output (output function #56) will be set and the CycleEnabled output (output function #55) will be cleared.

If the Begin Feed Angle option is selected, the Feed Initiate input needonly be set at the beginning of the Press Feed Angle.

Complete OutputsThe following four parameters refer to the operation of the threecomplete outputs (Batch Complete, Job Complete and Job QueueComplete. See page 43 for a complete list of output functions). There arethree ways to clear these outputs;

1. Use the Clear Complete Outputs input function (#94) which willclear all three outputs.

2. Enter Yes for the All Cleared At End Of Next Part parameter (seebelow).

3. Use the three Duration parameters listed below.

All Cleared At End Of Next Part

If you enter Yes for this parameter the Batch Complete output (outputfunction #57), Job Complete output (output function #58) and the JobQueue Complete (output function #59) will be cleared at the end of thenext part, regardless of whether or not duration times are being used toclear these outputs.

Batch Complete - Duration

If this parameter is non-zero (i.e. enabled), then the batch completeoutput will remain on for this amount of time unless it is cleared by theClear Complete Outputs input (input function #94) or at the end of thenext part that follows the completion of a batch.

Job Complete - Duration

If this parameter is non-zero (i.e. enabled), then the Job complete outputwill remain on for this amount of time.

Job Queue Complete - Duration

If this parameter is non-zero (i.e. enabled), then the Job Queue completeenhancements improvements output will remain on for this amount oftime.


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Select Serial Default Program By:This parameter allows you to select the default PCX program by either anidentifier (up to eight characters) or by the program number. If you selectID, you must enter an ID in the program screen of the program you wishto select.

These software selections have affect if program select lines (inputfunction #30) are assigned. Hardware lines will always override thesoftware selections.

Current Default Number

Enter the number of the PCX program you wish to select as the defaultprogram to be initiated by the program initiate input. If the programnumber you enter here also has an ID, it will appear in the CurrentDefault ID when online.

Current Default ID

Enter the program ID you wish to select exactly as you entered it in theprogram screen as the default program to be initiated by the programinitiate input.

Early Warning Part CountThis parameter sets the number of parts that are remaining in the batchcount when the Early Warning output comes on (see Early Warningoutput on page 46).

Feed Cycle TimeoutIf feed initiate does not occur within the time duration entered here, theFX/PCM-24 will F fault and stop motion. Once the fault is cleared, theprogram must be re-started and a subsequent cycle start is then neededto re-enable the press cycle. Entering 0 (zero) disables the timeout.

Manual Setup Mode DelaysThese delays are primarily used during setup and troubleshooting.

Reverse Jog Delay

This parameter is the delay time between a reverse jog is initiated andwhen motion actually begins. This is used to allow the anti-backup rollsto open before the reverse jog begins. Acceptable values are from 0 -65.535 seconds.


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Anti-Backup Close Delay

Delay time between when motion from the last reverse jog has stoppedand before the anti-backup rolls will be closed again. Acceptable valuesare from 0 - 65.535 seconds.

This could be dangerous if the delay is set for several secondsand the operator is unaware that the anti-backup rolls are goingto close automatically.

Feed Rolls Open Delay

Delay time between when the drive is inhibited and when the feed rollsopen. It is intended to keep the feed rolls from opening immediatelywhen the drive receives an inhibit input. This delay has no effect if themotor is turned off due to a drive control fault. Acceptable values arefrom 0 - 65.535 seconds.


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Loop Control ScreenThe voltage of the PCM-24 analog output in automatic mode isproportional to the average feed rate and is calculated by the PCM-24 justbefore each feed. To setup the analog loop parameters, choose the LoopControl option under the Drive Configuration menu in PCX.

Figure 7 Loop Control Screen

Maximum Loop SpeedThe first parameter entered in the loop control screen is the MaximumLoop Speed. This value reflects the maximum average feed rate, in userunits per minute, that the press will ever run. When running a cycle inthe automatic mode the PCM-24 calculates the average feed rate justbefore each feed and updates the analog output according to theequations found below.

Max Loop Speed Reference (Max Voltage)The value you enter here is the reference voltage associated with themaximum speed of the loop. The desired output voltage is always limitedbetween 0 volts and this value (Max Voltage). If a negative value isentered, the voltage will always be negative.


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Voltage Change Rate LimitThis parameter sets the Voltage Change Rate Limit which is themaximum allowable rate of change for the loop control voltage output.Entering a value of 0.0 volts/sec disables the limit.

The rate of change of the analog output is limited by the Voltage RateChange Limit (see below) which is defined in terms of volts/sec.

Loop Speed Increase/Decrease IncrementThe percentages you enter for these two parameters represent apercentage of the analog output voltage that will be used to increment ordecrement the loop speed by modifying the analog out voltage.

For Example, if the High or Low loop inputs (input functions 92 and 93respectively) are active, the analog output will be modified at thebeginning of each feed initiate as follows:

Relationships:

If the High Loop input is active:AOr = AOr (last value) + ( LI * AOr (last value) )

If the Low Loop input is active:AOr = AOr (last value) - ( LD * AOr (last value) )

Description Of Terms:AOs = 12 bit analog output voltage at start - up (volts).AOr = 12 bit analog output voltage while running (volts).CLS = Calculated line speed (user distance units per minute).CSR = Calculated strokes rate (strokes per minute).CV = Calculated voltage (volts).CSSR = Cycle Start Strokes Rate (strokes per minute).CSSR = Cycle Start Strokes Rate (strokes per minute).FL = Feed length (user distance units).LI = Loop Speed Increase (%).LD = Loop Speed Decrease (%).LS = Line speed (user distance units per minute).MV = Max loop speed reference voltage (volts).MS = Maximum loop speed (user distance units per minute).WF = Voltage weighting factor.

Cycle Start Strokes RateThis parameter is used to calculate the analog output voltage at startup.

When a new press feed cycle is started in automatic mode with a cyclestart input, the analog output voltage will be the voltage from the lastactive press feed cycle unless a Reset Analog Loop Control input isinitiated (Input Function #101).


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After a Reset Analog Loop Control is initiated and the next cycle isstarted, the Cycle Start Strokes Rate value is used to calculate the analogoutput voltage to be as follows:

Relationship:LS = CSSR * FLAOs = ( LS/MS )*MV = ((CSSR * FL)/MS)*MV

After the press feed is running in automatic mode, the analog outputvoltage will be updated during each cycle according to the calculationsdetailed in the target voltage weighting factor section.

Target Voltage Weighting FactorThe Target Voltage Weighting Factor is entered as a percentage from 0-100%. If the Voltage Weighting Factor is set to zero, the analog outputvoltage will be the same as the initial cycle startup analog voltage. Thisvalue is provided so you can affect the amount that the current runningrate will have on the analog output.

Relationships:CLS = CSR * FLCV = (CLS / MS) * MVAOr = ( WF * CV) + ( ( 1 - WF) * AOs )

As can be seen from the algorithm, if 0% is entered for the VoltageWeighting Factor (WF), the analog output start-up voltage is always usedand the calculated line speed is eliminated from the calculation. If 100%is entered for the Voltage Weighting Factor, the voltage will follow thecalculated voltage based solely on line speed. A Voltage Weighting Factorbetween 0% and 100% allows combinations of the two terms to be used.

Analog Jog VelocityThe Analog Jog Velocity defines the voltage that will be output in themanual mode when the appropriate input is received.

If the positive value of the Analog Jog Velocity is desired on the analogoutput, the Analog Loop Jog + input (Input Function #99) must be madeactive. If the negative value of the Analog Jog Velocity is desired on theanalog output, the Analog Loop Jog - input (Input Function #100) must bemade active.

The output voltage will be maintained as long as either input function isactive or until the automatic mode is re-entered. The automatic modewill always override the manual mode analog output. Note that as in theautomatic mode, the Voltage Rate Limit Factor will track and limit theanalog output voltage if non-zero.


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Drive Parameters ScreenThe Drive Parameters screen allows you to enter values that relate theFX Drive to your mechanical system. In this manual we describe only thefirst parameter Axis ID Description, all other parameters in the DriveParameters screen are explained in the PCX section of the FX Drivesmanual (P/N 400282-00).

Axis ID DescriptionThis function allows you to enter a unique, 32 character, alphanumericdescription for each axis in your system that will be displayed at the topof each PCX screen. The descriptions allow you to quickly identify an axisby it's function in a multi-axis system. The axis description will also bedisplayed to the right of the axis ID on the "Select Drive Screen" whenmore than one FX Drive is communicating with PCX.

Axis ID Setup

Move the cursor to the Axis ID Description line in the Parameters Menuand type the description for that axis. After you have typed thedescription, press the key to transmit the information to theDrive.

Because the Axis ID description is stored in the Application Module's non-volatile memory, the module will retain its Axis ID Descriptioninformation when moved to another FX Drive.

Figure 8 Drive Parameters Screen


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Master Axis ScreenAn external Master Axis can, by programming, become the time base formotion control of a Follower Axis (your FX Drive equipped with a PCM-24). The basis of operation is determined by the relationship of theexternal master axis encoder or drive, to the follower axis motor.

The Master Axis is typically an Emerson SCS-2 encoder which produces4000 steps per revolution or it can be a customer supplied encoder of anyline density yielding the appropriate steps per revolution.

Master Axis SetupThe base number system used for the FX Drive is binary and 12 bit.Resolution is one part in 4096. Since this number may be difficult to workwith because of user engineering units, drive electronics allow for aconversion to any number from 200 to 25,000 with the default being 4000.

Figure 9 Master Axis Screen

To set up a relationship between the Master Axis and the Follower Axis(your FX Drive and PCM-24), select Drive Setup, Drive Configuration,then Master Axis.

Slip Encoder Is Set To

Using the arrow keys to toggle between Encoder 1 and Encoder 2. Thisparameter selects the signal source used for slip compensation. If the slipencoder is defined as encoder 1, a second encoder (encoder 2) can be usedfor synchronization. If the slip encoder is changed from encoder 1 toencoder 2, the master signal source encoder is changed to encoder 1automatically.


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Encoder Steps Per N Revolutions

This parameter scales the number of encoder steps to the positioningdrive's user units. For example: If the encoder produces 4000 steps perrevolution which is equal to 1 inch of movement in your system, youwould enter the values shown in.

User Distance Per (N) Revolutions

This parameter sets the distance in user units your material or productwill travel based on the number entered for Encoder Steps Per NRevolutions.

Example: Your machine is designed so that .500 inches of materialmovement will cause the encoder to turn exactly 1 revolution. And theslip encoder produces 4000 steps per revolution. The User Distance PerRevolution is set to .500 and the Encoder Steps Per Revolutions is set to4000.

Signal Polarity

This parameter defines the direction of the slip encoder that correspondsto a positive motor position change. Clockwise is indicated with a (+);counterclockwise is indicated with a (-). Perspective is looking at theencoder or motor face.

Figure 10 CW Motion

Master Signal Source

Use the arrow keys to toggle between Encoder 1, Encoder 2 andUpstream Drive. This parameter selects the signal source used forsynchronization. If Encoder 1 or Upstream Drive is selected for mastersignal source, Encoder 2 is automatically used for slip compensation.Likewise, if Encoder 2 is selected for master signal source, Encoder 1 isused for slip compensation.

Referring to Figure 6 on the previous page, if Upstream Drive is selectedas the synchronization source, Encoder 1 could not be used for slipcompensation; therefore, Encoder 2 would be used for slip compensation.


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Signal Polarity

Defines the direction of the synchronization encoder that corresponds to apositive master position change. Clockwise is indicated with a (+);counterclockwise is indicated with a (-). CW and CCW motion of theMaster Axis is defined while facing the encoder shaft.

Signal Interpretation

Use the arrow keys to toggle between the choices. The SignalInterpretation feature allows you to define how the follower reacts toclockwise and counterclockwise motion of the synchronization encoder.

Mode #1 (+ and -): When the master axis moves either CW or CCW, thefollower axis will move in its commanded direction. If the master axischanges direction the follower axis will continue in the originalcommanded direction. The follower axis will not reverse direction.

Mode #2 (+): The follower will only react to synchronization pulses whenthe master axis runs in the CW direction. CCW master axis pulses areignored.

Mode #3 (-): The follower will only react to synchronization pulses whenthe master axis runs in the CCW direction. CW master axis pulses areignored.

Mode #4 (COMP +): The follower will only react to synchronizationpulses when the master axis runs in the CW direction. The drive countsthe pulses received in the CCW direction and ignores that exact numberof CW pulses before follower motion in the CW direction occurs.

This feature compensates for master axis motion in the opposite (CCW)direction. For example, the master stops, then inadvertently backs up dueto conveyer slack, vibration, etc.

Mode #5 (COMP -): The follower axis will only react to synchronizationpulses when the master axis runs in the CCW direction. The drive countsthe pulses received in the CW direction and ignores that exact number ofCCW pulses before follower motion in the CCW direction occurs.

This feature compensates for master axis motion in the opposite (CW)direction.

Signal For Sync Output From:

Use the arrow keys to toggle between the choices. If you select Motor,your FX Drive will output a sync signal to the next FX Drive based on theperformance of its own motor. If you select Upstream Drive, your FXDrive will output a signal that comes from the motor of the precedingamplifier.

Encoder pulses are passed to all amplifiers in the synchronization chain.How you answer this question has no effect on the encoder signal.

The next FX Drive and PCM-24 will only operate with this pulse train ifyou set that drive up with Drive Signal Source as Drive.


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Master Maximum Velocity

The master maximum velocity is the maximum frequency that the masteraxis signal source is expected to produce when running at its full speed.To calculate the master maximum velocity, use the following formula:

Master MaxVelocityMV MS

SecMin

=( )( )60

MV = Master Axis Maximum Velocity (RPM's)MS = Master Steps/Rev

If encoder is master: MS = (Encoder Line Density)*(4)

If drive is master: MS = 4096

For example: The master axis is a 1000 line encoder and rotates at amaximum speed of 3000 rpm, and, when quadratured, produces 4000steps per revolution. Then:

( )(Re )

,

3000 4000

60200 000

RPM Stepsv

SecondsSteps Per Second=

Maximum frequency intoPCM module cannotexceed 210 Khz orsteps/second.

This value is the master encoder velocity at which synchronized time baseand real time base are equal. This parameter is used to calculate actualfollower velocity while running in synchronized time base.

Sync Velocity User Units

This parameter sets the units to be associated with all sync velocities.User units can be any three letter combination, such as IPS (inches persecond), RPM (revolutions per minute), FPM (feet per minute), etc.

Sync Velocity Scaling (Max RPM = )

This parameter sets the sync velocity entry that will produce maximumvelocity of the drive when the master axis signal source is at maximumvelocity. When an index is running in sync time base, the velocity isspecified in user units.

The default value is 1.000. A setting of 0.500 in an index velocity meansthe drive will accel to half of maximum velocity.

External Mode Override

External mode override works in conjunction with input function #38 tooverride the current mode of operation. When input function #38 isassigned and active, the drive will exit its current operating mode anddefault to the mode selected with this parameter. There are three modesof operation, analog velocity, analog torque and bi-polar sync.


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Analog Velocity/Torque

When set to analog velocity or torque mode, the drive will respond to aconventional 10VDC signal. In either of the two analog modes a 10VDCsignal is equated to either (CW) or (CCW) maximum programmed velocityor maximum full peak torque rating.

If you enable analog torque mode and apply a voltage between 0 and 10VDC to the command connector the FX drive will attempt to producetorque equal to:

MaxTorqueAppliedVoltage

VDCActual Torque

10

=

If there is no physical resistance to the torque at the motor shaft, themotor will very quickly accelerate to maximum speed.

Bi-polar Sync (Electronic Line Shaft)

When set to bi-polar sync, this parameter allows for direct movement ofthe FX drive motor ratioed to the sync encoder. This mode moves themotor shaft in direct response to encoder or drive signals. This meansimmediate velocity without ramping in your FX drive. If the master axisaccelerates very quickly, your FX drive (follower axis) will try to followjust as quickly. Too fast an acceleration by the master axis could result inF (Follow Error) faults for the follower axis.

Bi-polar Sync Ratio (motor)

The Bipolar Sync Ratio is the relationship of the Follower Axis position tothe Master axis position. If the Bipolar Sync Ratio is set to 3, for every 1count of the Master Axis, there will be 3 counts of the Follower Axis.Thus, the Bipolar Sync Ratio would be 3:1.


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Programmable Limit Switches (PLS)Programmable Limit Switch (PLS) patterns can be updated at 16 specificmotor positions using the existing Programmable Output Lines (PGOs)and user units to define motor position. The pattern you set is the waythe lines will look after the motor enters that position range.

A PLS pattern consists of a specific combination of On, Off, and Don'tChange line conditions of the programmable output lines. Sixteendifferent patterns may be entered to occur at the intervals you specify.Patterns can be updated at 16 different motor positions. There are38 (6561) possible patterns available. You may use a maximum of16 output lines.

The default mask for programmable limit switch operation (all X's,meaning Don't Change the existing line condition) disables the PLSfunction. As the X's are changed to 1's or 's, the associated PLSpattern will become active at that motor position.

Motor position is referenced by user units. Once PLS patterns are set upthe motion range of the motor is divided into sections. When the specifiedsection is reached (from either direction), the output pattern associatedwith that range will activate the assigned output lines and programexecution will continue. Lines set to "X" will remain unchanged. The PLSpattern remains in that state until the next range is reached by virtue ofthe changing motor position. However, you may set a time delay to turnoff a particular pattern.

When a non-zero pulse width is entered for a given PLS pattern, thepattern will remain in that state for that amount of time. After the pulsewidth time has expired, the lines are set to all 's meaning "OFF". Linesmasked with "X" remain unchanged.

If another PLS range is reached before the pulse width time expires, thenew pattern is set immediately and the time delay is ignored.

PLS functions remain active once they are enabled. There is no way toremotely enable or disable this function after patterns have beenentered by PCX. The only way to disable the PLS function is through theInitialize Memory option: PLS Data.


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PLS SetupBefore setting up a PLS pattern you will need to assign one or moreoutput lines (either hardware or internal) as programmable outputs. Thisis done in the Drive Setup, Drive Configuration, Output Functions menu.Select Output Function 12, Programmable Outputs. After you enter theline number of the hardware or internal Output Line that is the first ofyour programmable output lines, enter the number (quantity) of lines youwant to use (maximum 16 lines) and press .

To set a Programmable Limit Switch Pattern, select Drive Setup, DriveConfiguration, Programmable Limit Switches. The screen you see willlook like Figure 21.

Figure 11 Programmable Limit Switch

Your cursor will highlight the starting point of the first position range(typically zero when starting out). Enter the first range starting positionincluding decimal point and then press the key. The cursor willmove to the Pattern Area and highlight the first column.

This column represents the first Programmable Output line that youassigned (that line number will be shown above next to the word"Pattern"). At this point, enter a 1 to turn a line On, a to turn a line Off,or an X for Don't Change this line.

Do not press the key at this point. You will notice that afterevery entry the cursor moves to the next column. Wait to press the key until you are finished entering or correcting the desiredpattern. When you have completed the pattern for this range, press the key and the cursor will move to the Pulse Width area.

If you enter a Pulse Width (or time delay) in seconds in this field, thepattern you have just entered will come on when the motor enters thisrange from either direction and stay on for the amount of time you enter.When the time expires, all lines marked with a "1" will be turned off.Lines with an "X" will not be changed.


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However, if the motor is moving through the range faster than the PulseWidth you have selected, the next range pattern will be set on the outputlines as soon as that range is entered. Only lines marked with "X" in thenext range will not be changed.

After you enter the pulse width (or for the pattern to remain until themotor enters the next range), press . The cursor will move to thenext PLS starting point.

In the example screen in Figure 11, assuming a 25 inch linear range isactive, the PLS pattern will show all lines off when the motor positiongoes below 2.000 in., including positions less than zero. The pattern willremain as in position 4, when the motor position is over 25.000 inches.

If PLS positions are entered such that the sections are out of sequentialorder, PCX immediately sorts the positions in ascending numerical orderafter you enter a position and updates the display automatically.

Remember that the pattern will change according to 1) the position themotor enters, and 2) the direction that position is approached from. If themotor moves from 3.000 inches to 1.000 inches, the pattern will go fromfour lines ON, four lines OFF to four lines OFF, four lines ON as theposition becomes less than 2.000 inches.


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Internal Input and Output LinesThis feature enables the drive to signal itself without using hardwareinput or output lines. For example; If your application requires the driveto be flagged that a particular step has been completed while a program isrunning, you can simply assign an internal output to flag an internalinput.

There are 16 internal input and 16 internal output lines available, givingyou access to a total of 32 input (16 hardware and 16 internal) and 24output (8 hardware and 16 internal) lines per FX Drive with a PCM-24.The internal input lines support Jump and Wait statement conditions.The Jump and Wait inputs can also be overlapped between the hardwarelines and the internal lines.

For example, if input function #28 (Jumps/Wait Inputs) is assigned tohardware line 17, and 8 input lines are selected, then the Inputs would beassigned to hardware lines 17-20 along with internal input lines I1-I4.Half would be assigned to hardware inputs and half would be assigned tointernal inputs (see Input Function screens below).

Figure 12 Hardware (External) Input line Assignments


35

Press the F2 key to display the internal output lines.

Figure 13 Internal Output Line Assignments

The maximum number ofPGO lines is 16; themaximum number ofJump/Wait Input lines is 8.

Similarly, the internal output lines support programmable outputs(PGOs). The PGOs can be overlapped between the hardware output linesand the internal output lines. For example, if output #12 (PGOs) isassigned to hardware line 9, and sixteen output lines are selected, thenthe PGOs would be assigned to hardware output lines 9, 10, 11, and 12,along with internal output lines 1 through 12.

Figure 14 Software (Internal) Input Line Assignments


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Figure 15 Internal (Software) Output Lines Assignments

The "internal" lines are assigned just as normal hardware lines with thefollowing differences:

Internal Inputs are designated by I1 through 16 (i.e., letter "I", notnumeral 1).

Internal Outputs are designated by O1 through O16 (i.e., letter "O", notnumeral 0).

All output lines, both hardware lines and internal lines, can be assignedto connect to input lines on the Input Function Screen. This allows you toattach a hardware or internal output line directly to an input line(hardware or internal) to allow outputs to trigger inputs without the needfor external wiring.

If you assign an internal or hardware output line to trigger a hardwareinput line, the LED on the FX Drive or PCM-24 associated with that linewill not glow when the logic makes the line active. Only externallysupplied current draw will cause the LED to light up.

Internal Input/Output Setup

To equip a hardware or internal output line that internally enables eithera hardware or internal input line, select Drive Setup, DriveConfiguration, Input Functions and move the cursor to the end of themenu to the section labeled "Output Connections".

If you want to assign a hardware or internal output line to an input line(either hardware or internal), move the cursor to the output line you wishto use and enter the number of the input line (1 - 8, 13 - 20 or I1 - I16)that you want the output line to connect to. The input line that youdesignate will be activated any time the output line is turned onregardless of the function that turns on the output line.


37

Figure 16 Output Connections To An Input Line

In Figure 20, hardware output line #9 is internally connected to inputline #1 and internal output line #O1 is connected to hardware input line#2. On the left side of the screen under "Input Assignments" the outputnumber is in parentheses to the right of the input it has been assigned to.

You can monitor function assignments to Internal Input and OutputLines by pressing the key. A second line listing will be displayed onthe left side of the screen, showing all the assignments for the internallines. If an input or output line, either hardware or internal, has so manyfunctions assigned to it that the listing scrolls off the PCX screen in theupper left corner, use the key plus the or arrow keys to scrollthrough all of the assignments.


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PCM-24 Input/Output FunctionsInput Functions

In order for the PCM-24/FXDrive to respond to an input,the selected line must draw aminimum of 2 mA. at 10.5 to30VDC for 3 to 7 ms.

The following Input functions are available in addition to the inputfunctions listed in the "FX Drives Setup and Programming Operator'sManual" (P/N 400282-00) when a PCM-24 module is employed with anFX Drive.

24 Remember Position

Stores the current position of the drive in a Return absolute index.(Default = Index 0). This index number may be changed in the SuspendFunction menu.

25 Return To Position

Returns to the position defined by Remember Position input. This inputuses the Return index which must be set up as an absolute index.

26 Clear End Of Sequence

Clears the End Of Sequence output. If not assigned, the End Of Sequenceoutput will automatically clear when the next motion occurs. If this inputis assigned, the output can only be cleared by activating a "Clear end ofsequence" input.

27 Clear Programmable Output

Clears a Programmable Output. Each assigned Programmable Outputrequires a separate "Clear Programmable Output" line which correspondsto the PGO's (output function #12) in the same order. If four lines areselected for PGO's, this input function requires four lines to clear thePGO's.

28 Wait/Jump Inputs

Used with the Wait For Input program function to stop programexecution until the input line assigned with External Input is activated,and with the Jump program command to change program flow based online conditions. Sets the starting Input Line number for multipleWait/Jump Input Lines. If your system requires four Wait for ExternalInput lines, you could assign any four consecutive Input Lines.

29 Program Initiate

Executes the selected program. Edge Sensitive function. Must be takenfrom low level to high level to be recognized.


39

30 Program Select Lines

This input function allows you to select a program with Input Lines andsets the starting Input Line number for a number of Program SelectLines. For example: If your system requires four program select lines, youcould assign any four consecutive Input Lines. If you assign the programselect function to Input Line #5, then entered a 4 as the number ofProgram Select Lines, the Program Select function would now beassigned to Input Lines #5, 6, 7 and 8. You could now select programs 0through 15.

The default format of the program select lines is binary. That is, the firstline that you assign has a value of 1, the second a value of 2, the third avalue of 4, the fourth a value of 8 and so on. The program numberselected is the sum of the values of the lines activated.

Selecting program 5 in this example would require activating lines

5 (value 1) and 7 (value 4) while activating the line assigned to

Input Function 29, Program Initiate. If no lines are activated, this

is the same as selecting Program #0.

31 Suspend Program

Stops the execution of a program until the input line assigned withResume is activated. See Suspend/Resume Functions Section of thismanual for a complete discussion.

32 Resume Program

Resumes the execution of a suspended program. See Suspend/ResumeFunctions Section of this manual for a complete discussion.

33 Abort Suspend

Clears the In Suspend output and returns the drive from a suspend cycleto normal operation without the need to "resume" and completion of thesuspended program. (Also see "Suspend/resume Functions" in Programsection).

34 Clear End Program

Clears the End Of Program output. If not assigned, the End Of Programoutput will automatically clear when further motion is initiated. If thisinput is assigned, an input is required to clear the output.

35 Clear End Program Count

Clears the End Of Program Count output. If not assigned, the End OfProgram Count output will automatically clear when the next motionoccurs. If this input is assigned, an input is required to clear the output.

36 Clear All Prog Outputs

When the line assigned to this function is activated, this function willclear (set to OFF) all programmable output lines. ( See Input function #27to clear individual programmable output lines.)


40

38 External Mode Override

An active input allows direct and immediate movement of the FX Drivemotor using the Bi-Polar Sync Ratio setup in the Master Axis screen (seesection "Master Axis Description & Setup").

78 Clear Program Error

This input is used to clear the Program Error output (Output Function#46). If this function is assigned, this input is required to clear the output.

81 Automatic Mode

If this input is on, the PCM-24 will enter the Automatic mode. If thisinput is cleared, the PCM-24 will enter Manual mode.

82 Setup Mode

If the Setup Mode input is set and the Automatic Mode input is clear,then setup mode is entered. When the setup mode is entered, the SetupMode output is on and the drive position is loaded to 0.

When the PCM-24 is in setup mode the drive can be jogged only a singlefeed length in the forward direction or minus one feed length in thereverse direction.

In Setup mode the Jog Forward and Jog Reverse inputs perform a jogfeed. If Jog Forward is the first jog feed after entering Setup Mode, thenthe PCM-24 will restrict motion between the zero position and plus onefeed length. If Jog Reverse is the first jog feed after entering Setup Mode,then the PCM-24 will restrict motion between the zero position andminus one feed length.

The PCM-24 will only move beyond a single feed length if a Feed Initiateoccurs. After a Feed Initiate, the drive position is again loaded to 0 andthe PCM-24 will allow movement of up to plus or minus one more feedlength. The PCM-24 will remain in the Setup mode until either the Setupinput is cleared or the Automatic input is set.

83 Feed Angle/Initiate

The rising edge of the Feed Angle/Initiate input will start a feed cycle. InFull Feed Angle Mode the Feed Angle/Initiate input should stay set forthe entire press feed angle. If the Feed Angle/Initiate input is clearedbefore the press feed movement is complete, the drive will be stopped andthe Feed Fault output (output function #56) will turn on.

In Begin Feed Angle Mode, the Feed Initiate input need only be set atthe beginning of the press feed angle.

84 Next Part

When in Setup mode, the rising edge of the Next Part input will cause theFX Drive motor to move forward at the Jog Feed Velocity to the end of thecurrent range (or forward to the jog feed starting position if Jog Reversewas done when the drive first entered the setup mode).


41

85 Previous Part

If in Setup mode, the rising edge of the Next Part input will cause thedrive to move in the reverse direction at the Jog Feed Velocity to the jogfeed starting position (or to a position of minus one feed length if JogReverse was done when the drive first entered the setup mode).

86 Cycle Start

The rising edge of the Cycle Start input, when the Cycle Stop input isclear, causes the drive to set the Cycle Enabled output and allow the FeedAngle/Initiate input to start a feed cycle. Additionally, if the BatchComplete output is set, the part count will be set to zero, the BatchComplete output will be cleared and the Early Warning output will becleared.

If the Batch Queue Complete output is set the Batch Queue Completeoutput will be cleared.

Many applications typically willassign the Cycle Start inputfunction as well as the ProgramInitiate function to the sameinput line so the two areachieved simultaneously.

If feed initiate does not occur within the time called out in the Feed CycleTimeout, then the PCM-24 will F fault and stop motion. Once the faultis cleared, the program must be re-started and a subsequent cycle start isthen needed to re-enable the cycle.

87 Cycle Stop

The rising edge of the Cycle Stop input causes the drive to clear the CycleEnabled output and not allow the Feed Initiate input to start the feedcycle. The PCM-24 will stop the drive at the end of the part beingproduced (after all feeds in the part(job) have been completed). The cyclewill remain disabled as long as the Cycle Stop input is set.

88 Reset Part Count

The rising edge of the Reset Part Count input will set the current partcount to zero.

89 Reset Batch Count

The rising edge of the Reset Batch Count input will set the current batchcount and the current part count to zero and clear the Batch Completeoutput.

90 Reset Job Queue Count

The rising edge of the Reset Job Queue Count input will set the currentJob Queue Count, current batch count and the current part count to zeroand clear the Batch Complete and Job Queue Complete outputs'.

91 Count Inhibit

This input inhibits the incrementing of the part count and batch countcounters as long as the input is active.


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92 High Loop

Before the start of each feed, the PCM-24 will check the High Loop input.If the High Loop input is set, then the analog output voltage is increasedby the loop speed increase increment percentage defined in PCX (up to100% of the maximum voltage allowed by the user). This input is typicallyset by a sensor that indicates when the loop of the material beingsupplied to the press feed is almost empty.

93 Low Loop

Before the start of each feed, the PCM-24 will check the Low Loop input.If the Low Loop input is set, then the analog output voltage is decreasedby the loop speed decrease increment percentage defined in PCX (up to100% of the maximum voltage allowed by the user). This input is typicallyset by a sensor that indicates when the loop of the material beingsupplied to the press feed is almost too full.

94 Clear "Complete" Outputs

This input clears the batch complete, job complete, and job queuecomplete outputs.

95 Open Feed Rolls

If the PCM-24 is in Manual mode and the Close Feed Rolls input is clear,then the rising edge of the Open Feed Rolls input will open the feed rollsand clear the Feed Rolls Closed output.

96 Close Feed Rolls

If the PCM-24 is in Manual mode and the Open Feed Rolls input is clear,then the rising edge of the Close Feed Rolls input will close the feed rollsand set the Feed Rolls Closed output.

97 Open Anti-backup Rolls

If the PCM-24 is in Manual mode and the Close Anti-backup Rolls inputis clear, then the rising edge of the Open Anti-backup Rolls input willopen the anti-backup rolls and set the Anti-backup Rolls Opened output.

98 Close Anti-Backup Rolls

If the PCM-24 is in Manual mode and the Open Anti-backup Rolls andJog Reverse inputs are clear, then the rising edge of the Close Anti-backup Rolls input will close the anti-backup rolls and will set the Anti-backup Rolls Closed output.

99 Analog Loop Jog +

If the PCM-24 is not executing a cycle in the automatic mode, the risingedge of the Analog Loop Jog + input will cause the analog output voltageto be set to the Analog Jog Velocity voltage as defined in the PCX loopcontrol screen. While cycles in the automatic mode are running, theanalog output is set through the automatic mode calculations.


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100 Analog Loop Jog -

If the PCM-24 is not executing a cycle in the automatic mode, the risingedge of the Analog Loop Jog - input will cause the analog output voltageto be set to the negative value of the Analog Jog Velocity voltage asdefined in the PCX loop control screen. While cycles in the automaticmode are running, the analog output is set through the automatic modecalculations.

101 Reset Analog Loop Cntl

The rising edge of the Reset Loop Control will set the current targetvoltage based on the Cycle Start Strokes per minute parameter and thefirst feed length of the current job.

PCM-24 Output FunctionsThe following list of output functions are available in addition to theoutput functions listed in the "FX Drives Setup and ProgrammingOperator's Manual" (P/N 400282-00) when a PCM-24 is employed with anFX Drive.

3 End of Index (Feed Complete )

The Feed Complete output is set at the completion of the feed (i.e., atcompletion of an index). It is cleared automatically when the next motioncommand is initiated.

11 End Of Sequence

This output comes On after the completion of a motion sequence beforethe last dwell time (if any). A motion sequence is completed when aHome, Index, and/or Program or a combination thereof, is executed andno further motion commands are given. This output turns OFFautomatically with the next motion or when the Clear End Of Sequence isused.

12 Programmable Outputs

The output lines assigned this function can be turned On or Off with theUpdate Outputs programming function.

13 End Of Program

This output is activated after each completion of all steps (motion andnon-motion) in a Program. It is automatically deactivated with the nextmotion or when the Clear End Of Program input is used.

14 End Of Program Count

This output is activated only after a program is executed the number oftimes specified by the Program Count. It is automatically deactivatedwith the next motion or when the Clear End Of Program Count is used.


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15 In Suspend

This output is activated when the Suspend Program function is active.Also see Suspend/Resume Functions section of this manual for a completediscussion.

16 End of Home (1)

This output comes On after the completion of a Home 1 cycle. It is turnedOff automatically with the next motion or when the Clear End Of Homeinput is used.

17 At Sync

This output is active during a program when an index with ExternalTime base reaches sync. velocity.

18 Sync Fault Flying Cutoff Fault

This output indicates that the programmed cut length reached a countthat should have initiated another flying cutoff but the FX drive was notin position to initiate the flying cutoff.

29 Maximum Slip

This output is activated when the maximum slip value (set in the limitsdialog box) is exceeded by the slip encoder. If the system sees this limitexceeded it will stop and display an "F" in the diagnostic window on thedrive.

30 Re-Index Maximum

This output will be activated when the maximum number of re-indexes isreached at the end of an index that is operating in re-index mode. See Re-Index dialog box in the PCM-24 manual.

31 Position Window Timeout

This output will be set if the feed is not within its feed tolerance (withinthe In Position Range) for a set time (the In Position Time) before themaximum time limit expires.

45 Out Of Index

his output is activated if the motor moves past the end of an index duringa fault initiated suspend. It will also be activated if the motor has movespast the fault position.

46 Program Error

This output is activated when a math error occurs in a program, however,program execution is not interrupted. You can view the diagnostics screenby pressing the key to determine the type of math error. Thisoutput is cleared using the Clear Program Error Input.

48 In Automatic Mode

The Automatic output is set when the drive is in Automatic mode.


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49 In Manual Mode

The Manual output is set when the drive is in Manual mode (includingSetup mode).

50 In Setup Mode

The Setup Mode output is set when the drive is in Setup Mode.

51 Feed Rolls Closed

The Feed Rolls Closed output is set when the feed rolls are to be closed.

52 Anti-backup Rolls Open

The Anti-backup Rolls Opened output is set when the anti-backup rollsare to be opened.

53 Feed In Motion

The Feed In Motion output is set whenever the actual velocity is greaterthan 1 RPM. This includes synchronized motion.

54 Permit Press

The Permit Press output is set when the press feed drive is ready to allowthe press to punch. The timing of this signal is affected by whether thePCM-24 is configured to Feed Before Press or to Press Before Feed.

55 Cycle Enabled

The Cycle Enabled output is set when it is possible to initiate a feed cyclewith the Feed Initiate input. This output is cleared with the Cycle Disableinput or when a batch is complete.

56 Feed Fault

The Feed Fault output is set if the Feed Initiate input is cleared beforethe actual feed velocity is less than 1 RPM (i.e., before feed complete)when the Feed Initiate is configured as a Full Feed Angle.

57 Batch Complete

The Batch Complete output is set when the part count is equal to thebatch quantity. Re-entering the feed cycle via a Cycle Enable input aftera completed batch will reset the part count and clear the Batch Completeoutput. The batch complete function may be disabled by setting the batchquantity to zero.

If the batch complete output duration is non-zero (i.e. enabled), then thebatch complete output will only remain on for this amount of time. Allother logic to clear the Batch Complete output will be disabled.

If the batch count of the current job is zero, the batch completed outputwill not be activated.


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58 Job Complete

The Job Complete output is set when all feeds in the job have beencompleted. Re-entering the feed cycle via a Cycle Enable input when theJob Complete output is set will restart the job and clear the Job Completeoutput.

If the job complete output duration is non-zero (i.e. enabled), then thebatch complete output will only remain on for this amount of time. Allother logic to clear the Job Complete output will be disabled.

59 Job Queue Complete

The Job Queue Complete output is set when all jobs in the job queue havebeen completed. Re-entering the feed cycle via a Cycle Enable input whenthe Job Queue Complete output is set will restart the queue and clear theJob Queue Complete output.

If the job queue complete output duration is non-zero (i.e. enabled), thenthe batch complete output will only remain on for this amount of time. Allother logic to clear the Batch Complete output will be disabled.

60 Early Warning

The Early Warning output is set when the number of parts remaining inthe batch is less than or equal to the early warning count. The earlywarning output will be cleared when the batch has been completed. ThisEarly Warning function is disabled by setting the early warning count orthe batch quantity to zero.


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Indexes Using A PCM-24Registration, feed to sensorand Rotary index types cannot be used with the slipcompensation feature.

Indexes in a PCM-24 Press Feed application are used to define theDistance, Velocity, Dwell Time, Time Base, Accel and Decel Times andother parameters that define how the Servo Feed operates.

Two additional index parameters (Continuous Compensation and Re-Index Compensation) are available when using a PCM-24 module with abasic FX Drive. An index can be set up to operate in continuouscompensation, re-index compensation or in both modes simultaneously.The parameters needed to setup your PCM-24 to run in slipcompensation mode are located in the Re-index screen (see Re-indexscreen on page 49). For a complete description of indexes, refer to thePCX section of the FX Drives manual P/N 400282-00.

Figure 17 Index Screen - Slip Compensation Features

Continuous Compensation ModeDuring a continuous compensation index, the drive constantly monitorsfeedback from the slip encoder and the motor resolver. The drivecom

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